Connector

Abstract: This invention prevents a wrong contact of terminals when one of a pair of connector housings is inserted into the other housing in a slanted position. In the connector of this invention, a female connector housing 12 is provided on opposite ends with guide ribs 21 which extend in an insertion direction and serve as guide elements when the female connector housing 12 advances into a hood 13. The female connector housing 12 is provided with a wedge like resistance-applying projection 24 which extends vertically while a male connector housing 11 is provided on an interior of the hood 13 with a groove in which the projection 24 advances. Upon insertion of the female connector housing 12, the projection 24 press-contacts with a slot 25 so as to generate an insertion resistance, thereby correcting an imbalance of the insertion resistance of the terminals 14.

Description: This invention relates to a connector which is coupled by means such as a lever and the like. There is a lever type or bolt type connector in the connector with the coupling means. The connector has an advantage in that it can be coupled and detached by a small force and can be applied to a multipole (more than twenty) connector. For example, a basic construction of a lever type connector is known in Japanese Patent Public Disclosure No. 4-62772 (1992). For convenience of explanation, a prior lever type connector will be explained below by referring to FIGS. 5 and 6. FIGS. 5A to 5D are schematic side elevational views of a prior lever type connector, illustrating a principle of the connector. FIGS. 6A to 6C are schematic longitudinal cross sectional views of the prior lever type connector, illustrating a problem in the prior connector. As shown in FIG. 5A, the prior lever type connector comprises a female connector housing 1 in which a number of female terminals are mounted and a male connector housing 2 in which a number of male terminals to be inserted into the female terminals are mounted. A lever 3 provided with a cam groove 3a which effects a "lever action" is rotatably attached to the male connector housing 2. A cover 4 to be put on the female connector housing 1 is provided with engaging projections 4a at opposite center lower side walls. In order to couple the connectors 1 and 2 to each other, as shown in FIG. 5B, the engaging projection 4a on the cover 4 is engaged with the cam groove 3a in the lever 3 and then the lever 3 is turned to an anticlockwise direction shown by an arrow. The cover 4 and female connector housing 1 are inserted into the male connector housing 2 by a cam action of the cam groove 3a. When the lever 3 is further turned to the anticlockwise direction from a position shown in FIG. 5C to a position shown in FIG. 5D, the terminals in the connector housings 1 and 2 are interconnected against a mechanical insertion resistance, thereby finishing to couple the connectors. The terminals mounted in the connector housings 1 and 2 are not always limited to single kind and uniformly distributed terminals. For example, as shown in FIG. 6A, there is a hybrid type connector having the male connector housing 2 in which a few terminals 5 for an electrical power supply and many terminals 6 for a signal transmission are mounted. Since the many terminals 6 for a signal transmission are disposed at the right side in the drawing in the hybrid type connector, a mechanical insertion resistance upon insertion of the female connector housing 1 is imbalanced in the right and left areas so that the resistance in the right area is larger than that in the left area. The female connector housing 1 is inserted into the male connector housing 2 while being inclined on account of such imbalance of the insertion resistance. Consequently, the female connector housing 1 is finally coupled to the male connector housing 2 with the housing 1 being inclined in the housing 2 as shown in FIG. 6C. This causes a problem in which the signal terminals 6 are incompletely inserted into and contacting with the mating terminals. Even if such imbalance of the insertion resistance is caused in a hand-insertion type connector, it may be relatively easily corrected by a worker since he or she can feel the imbalance of the insertion resistance. However, in the lever type connector wherein the female connector housing 1 is pushed down by the coupling mechanism which utilizes the "lever action" of the lever 3, the worker can not feel the imbalance. Consequently, the worker will mistake an incomplete coupling of the connector for a complete coupling even if the cause of the incomplete coupling is in the connector. We are aware of US-A-5137467 which forms the pre-characterising portion of Claim 1. According to our invention in a connector wherein each of a pair of connector housings is provided with a plurality of terminals and said terminals are interconnected against their mechanical insertion resistance by forcing said connector housings to be displaced in a coupling direction by means of a coupling mechanism, the mechanical insertion resistance is lower in some areas relative to other areas of the connector, and resistance-applying means are provided on said connector housings at areas associated with a lower insertion resistance of said terminals so as to give a balanced resistance and prevent inclined incomplete coupling of one housing relative to the other housing. Thus both connector housings are prevented from being coupled to each other in an inclined portion. The terminals are therefore prevented from being incompletely coupled even if there is an imbalance in insertion resistance. This ensures that incomplete contact of the terminals cannot occur. The resistance-applying means include a wedge-like piece preferably on the one of said connector housings and a groove on the other of said housing. Some embodiments of our invention are illustrated in the accompanying drawings in which:- Figure 1 is an exploded perspective view of an embodiment of a connector of the present invention; Figure 2 is a bottom view of a female connector housing taken along lines II-II in Figure. 1; Figure 3 is a fragmentary cross sectional view of a male connector housing taken along lines III-III in FIG. 1; Figures 4A to 4C are longitudinal cross sectional views of an embodiment, illustrating processes of inserting the female connector housing; Figures 5A to 5D are a schematic side elevational view illustrating a principle of a prior level type connector; and FIGS. 6A to 6C are a schematic longitudinal cross sectional view illustrating a problem in the prior lever type connector. An embodiment of a connector of the present invention will be described below by referring to FIGS. 1 to 4. A general construction of the connector is shown in FIG. 1. The connector comprises a male connector housing 11 and a female connector housing 12. The male connector housing 11 has a hood 13 which receives the connector housing 12 and mounts a number of male terminals 14 (see FIG. 4A). Relatively large terminals 14a for an electrical power supply and relatively small terminals for a signal transmission out of the male terminals 14 are arranged at a left half area and a right half area in FIG. 4A. The hood 13 of the male connector housing 11 is provided with lever bearing bosses 15 on opposite side walls thereof. An actuating lever 16 having two legs 16a is rotatably attached to the male connector housing 11 with the legs 16a being engaged with the bosses 15. Each leg 16a is provided with a cam groove 17 having a given arcuate shape around the lever bearing boss 15. On the other hand, the female connector housing 12 has a size sufficient to be inserted into the hood 13 of the male connector housing 11. Female terminals not shown are adapted to be connected to the male terminals 14 including power terminals 14a and signal terminals 14b are mounted in the female connector housing 12. A cover 19 is put on the housing 12 so as to cover electrical cables 18 which are connected to the female terminals and drawn out of an upper portion of the female connector housing 12. A pair of cam follower bosses 20 are provided on center side walls of the cover 19 and the bosses 20 together with the actuating lever 16 constitute a coupling mechanism. That is, when the female connector housing 12 is inserted into the hood 13 of the male connector housing 11 with the cover 19 being attached to the housing 11, a distance between the legs 16a of the actuating lever 16 are widened by the cam follower bosses 20 and the bosses engage with the cam groove 17, respectively. When the lever 16 is turned with the bosses 20, engaging with the cam groove 17, the bosses 20 are pushed down by the cam groove 17 so that the female connector housing 12 is displaced in the hood 13 against a mechanical insertion resistance of the female and male terminals. Finally, the terminals are completely coupled. As shown in FIGS. 4 and 2, the female connector housing 12 is provided on opposite side ends with four guide ribs 21. Two guide ribs 21 on the right side end in FIG. 4A are moved while contacting with guide projections- 22 provided on right end interiors of the hood 13 when the female connector housing 12 advances into the hood 13. The hood 13 is provided on the interior with guide grooves 23 which extend vertically (see FIGS. 3 and 1). When the female connector housing 12 is inserted into the hood 13, the two guide ribs 21 on the left side in FIG. 4A is inserted into and moved in the guide grooves 23. The female connector housing 12 is provided on the left end wall in FIGS. 2 and 4A with two resistance-applying projections 24 which extend vertically and constitute a part of resistance-applying means. The hood 13 of the male connector housing 11 is provided on the interior with two slots 25 associated with the projections 24. The slots 25 extend in the interior of the housing 11 in an inserting direction of the female connector housing 12, so that a depth of the slots 25 does not alter in the insertion direction. However, an end face of the projection 24 (left end in FIG. 4A) is slanted downwardly in the inserting direction from a given position thereof so as to form a wedge shape. In the above construction, a distribution density of the male terminals 14 is lower in a left half area in the hood 13 (an area of arranging the few power terminals 14a) than that in a right half area in the hood 13 (an area of arranging the many signal terminals 14b). Thus, when the female 12 is inserted into the hood 13 of the male connector housing 11 by actuating the lever 16, the mechanical insertion resistance associated with connection of the terminals becomes larger in the right half area than in the left half area. Heretofore, the female connector housing has been inserted into the male connector housing as it is slanted in the prior connector. Accordingly, there is a problem of a contact failure in a part of the terminals. On the contrary, according to the embodiment, since the female connector housing 12 is provided with the resistance-applying projections 24, the above problem can be solved as follows. When the female connector housing 12 is inserted from a position shown in FIG. 4A into the hood 13, firstly each guide rib 21 on the female connector housing 12 is guided by the guide projection 22 and guide groove 23 in the hood 13 and the resistance-applying projection 24 on the female connector housing 12 begins to advance in the slot 25. At this stage, since the projection 24 on the female connector housing 12 is tapered, the projection 24 does not press-contact with the bottom in the slot 25 and is not subject to the mechanical insertion resistance. However, as shown in FIG. 4B, when the female connector housing 12 is inserted in the hood 13 to a position where the terminals begin to interconnect, the projection 24 press-contacts with the bottom in the slot 25 and the mechanical insertion resistance thus generated is applied to the female connector housing 12. Although the female connector housing 12 is pushed toward the right in the drawing due to such press-contact of the projection 24 with the slot 25, the female connector housing 12 is not displaced to the right since the housing is limited to move vertically by an engagement of the guide ribs 21 with the guide grooves 23. The resistance-applying projection 24 is disposed at the left end of the hood 13 in opposition to the right end where the signal terminals 14b with a large mechanical insertion resistance is disposed. Thus, a distribution of insertion resistance upon inserting the female connector housing 12 is corrected so that the resistance is balanced at the right and left ends. Consequently, the female connector housing 12 advances in the hood 13 in the inserting direction without slanting. Finally, as shown in FIG. 4C, a lower end face of the female connector housing 12 entirely contacts with the bottom of the hood 13. Accordingly, all terminals mounted in the connector housings 11 and 12 are interconnected at an even depth. It is possible to prevent contact failure due to incomplete insertion of the terminals. The present invention should not be limited to the above embodiment. For example, the present invention can carry out the following alternatives: (a) Although the above embodiment is applied to a lever type connector, the present invention may be generally applied to a connector in which female and male connector housings are forcibly interconnected by a coupling mechanism utilizing a bolt; (b) Although the above embodiment is applied to a hybrid connector having large power terminals and small signal terminals, the present invention may be applied to a connector in which a distribution of insertion resistance is imbalanced due to an uneven density of arrangement of a single kind of terminal; (c) Although the female connector housing 12 is provided with a wedge like resistance-applying projection 24 in the above embodiment, the hood 13 may be provided with a wedge like projection which contacts with the female connector housing 12 while the housing 12 may be provided with a portion which applies an insertion resistance to the housing 11. Also, the resistance-applying element against displacement of the housing is not limited to a wedge shape. It may be any means for applying a resistance against displacement of the housing, such as a friction means; (d) Although the actuating lever 16 is attached to the male connector housing 11 and the cam follower boss 20 is provided on the cover 19 mounted on the female connector housing 12 in the above embodiment, the lever may be attached to one of the connector housings and the cam follower boss which directly engages with the lever may be provided on the other connector housing. Also a combination of the lever and cam follower boss may be reversed in the above embodiment. That is, the lever may be attached to the female connector housing while the cam follower boss may be provided on the male connector housing.

Claims: A connector wherein each of a pair of connector housings (11, 12) is provided with a plurality of terminals (14) and said terminals (14) are interconnected against their mechanical insertion resistance by forcing said connector housings (11, 12) to be displaced in a coupling direction by means of a coupling mechanism (16), the mechanical insertion resistance is lower in some areas relative to other areas of the connector, characterised in that resistance-applying means (24, 25) are provided on said connector housings (11, 12) at areas associated with a lower insertion resistance of said terminals (14) so as to give a balanced resistance and prevent inclined incomplete coupling of one housing (11) relative to the other housing (12). A connector according to Claim 1, wherein said resistance-applying means (24, 25) include a wedge-like piece (24) on one of said connector housings (11, 12) and a groove (25) on the other of said housings (12, 11).

Inventors: FUKAMACHI MAKOTO, NAKATA HIROYUKI, NANKOH YOUICHI, TANIUCHI OSAMU, FUKAMACHI, MAKOTO, NAKATA, HIROYUKI, NANKOH, YOUICHI, TANIUCHI, OSAMU, FUKAMACHI, MAKOTO, C/O SUMITOMO WIRING SYST., LTD., NAKATA, HIROYUKI, C/O SUMITOMO WIRING SYST., LTD., NANKOH, YOUICHI, C/O SUMITOMO WIRING SYST., LTD., TANIUCHI, OSAMU, C/O SUMITOMO WIRING SYST., LTD.
Applicants: SUMITOMO WIRING SYSTEMS, SUMITOMO WIRING SYSTEMS, LTD.
Application year: 1994
Main classification: H01R13
IPC codes: H01R13